US7771887B2 - Metal hydride fuel storage and method thereof - Google Patents

Metal hydride fuel storage and method thereof Download PDF

Info

Publication number
US7771887B2
US7771887B2 US12/409,392 US40939209A US7771887B2 US 7771887 B2 US7771887 B2 US 7771887B2 US 40939209 A US40939209 A US 40939209A US 7771887 B2 US7771887 B2 US 7771887B2
Authority
US
United States
Prior art keywords
substrate
cavity
pressure relief
relief structure
apparatus recited
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US12/409,392
Other versions
US20090184008A1 (en
Inventor
Jeffrey D. Morse
Alan F. Jankowski
Conrad Yu
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Lawrence Livermore National Security LLC
Original Assignee
Lawrence Livermore National Security LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lawrence Livermore National Security LLC filed Critical Lawrence Livermore National Security LLC
Priority to US12/409,392 priority Critical patent/US7771887B2/en
Publication of US20090184008A1 publication Critical patent/US20090184008A1/en
Application granted granted Critical
Publication of US7771887B2 publication Critical patent/US7771887B2/en
Assigned to U.S. DEPARTMENT OF ENERGY reassignment U.S. DEPARTMENT OF ENERGY CONFIRMATORY LICENSE (SEE DOCUMENT FOR DETAILS). Assignors: LAWRENCE LIVERMORE NATIONAL SECURITY, LLC
Assigned to LAWRENCE LIVERMORE NATIONAL SECURITY, LLC reassignment LAWRENCE LIVERMORE NATIONAL SECURITY, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: THE REGENTS OF THE UNIVERSITY OF CALIFORNIA
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04082—Arrangements for control of reactant parameters, e.g. pressure or concentration
    • H01M8/04201—Reactant storage and supply, e.g. means for feeding, pipes
    • H01M8/04216—Reactant storage and supply, e.g. means for feeding, pipes characterised by the choice for a specific material, e.g. carbon, hydride, absorbent
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/06—Combination of fuel cells with means for production of reactants or for treatment of residues
    • H01M8/0606—Combination of fuel cells with means for production of reactants or for treatment of residues with means for production of gaseous reactants
    • H01M8/065—Combination of fuel cells with means for production of reactants or for treatment of residues with means for production of gaseous reactants by dissolution of metals or alloys; by dehydriding metallic substances
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49108—Electric battery cell making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49108—Electric battery cell making
    • Y10T29/4911—Electric battery cell making including sealing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49108—Electric battery cell making
    • Y10T29/49115—Electric battery cell making including coating or impregnating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49982—Coating

Definitions

  • This invention relates to fuel cells.
  • Work is commonly derived from fuel by a combustion process which uses the pressure of expanding gases to turn a turbine or move a reciprocating piston and, ultimately, to provide torque to a driveshaft. This torque is then usually used for propulsion or to generate electrical power. In the latter case, the electrical power is often reconverted into mechanical work.
  • An aspect of the invention includes: an apparatus comprising a first substrate having (1) a cavity, (2) one or more resistive heaters, and (3) one or more electrically isolating, heat conducting coatings; a second substrate having (1) an outlet comprising (a) a hydrogen permaselective membrane and (b) a thick film porous material that forms a pressure relief structure and (2) one or more electrically isolating, heat conducting coatings, wherein the second substrate is bonded to the first substrate forming a sealed volume within the cavity; and a metal hydride material contained within the cavity.
  • a further aspect of the invention includes a method comprising forming a first substrate having a cavity; positioning one or more resistive heaters in the cavity; coating the cavity and the resistive heaters with one or more materials that are capable of (1) electrically isolating the resistive heaters and (2) conducting heat; filling the cavity with a metal hydride material; forming a second substrate having (1) an outlet comprising (a) a hydrogen permaselective membrane and (b) a thick film porous material that forms a pressure relief structure and (2) one or more electrically isolating, heat conducting coatings; and sealing the cavity by bonding the second substrate to the first substrate.
  • Another aspect of the invention includes an apparatus comprising a first substrate having an array of cavities containing (1) one or more resistive heaters, and (2) one or more electrically isolating, heat conducting coatings; a second substrate having (1) an array of outlets each comprising (a) a hydrogen permaselective membrane and (b) a thick film porous material that forms a pressure relief structure and (2) one or more electrically isolating, heat conducting coatings, wherein the second substrate is bonded to the first substrate forming a sealed volume within the array of cavities; and a metal hydride material contained within the array of cavities.
  • Another aspect of the invention includes an apparatus comprising a first substrate having (1) a cavity, (2) one or more resistive heaters, and (3) one or more coatings forming a diffusion barrier to hydrogen; a second substrate having (1) an outlet valve comprising a pressure relief structure and (2) one or more coatings forming a diffusion barrier to hydrogen, wherein said second substrate is coupled to said first substrate forming a sealed volume in said cavity; a metal hydride material contained within said cavity; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.
  • Another aspect of the invention includes an apparatus comprising: a first substrate having an array of cavities containing (1) one or more resistive heaters, and (2) one or more electrically isolating, heat conducting coatings; a second substrate having (1) an array of outlets each comprising a pressure relief structure and (2) one or more electrically isolating, heat conducting coatings, wherein said second substrate is coupled to said first substrate forming a sealed volume in said array of cavities; and a metal hydride material contained in said array of cavities; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.
  • Another aspect of the invention includes an apparatus comprising: a first substrate having an array of cavities containing (1) one or more resistive heaters, and (2) one or more coatings forming a diffusion barrier to hydrogen; a second substrate having (1) an array of outlets each comprising a pressure relief structure and (2) one or more coatings forming a diffusion barrier to hydrogen, wherein said second substrate is coupled to said first substrate forming a sealed volume in said array of cavities; and a metal hydride material contained in said array of cavities; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.
  • Another aspect of the invention includes a method comprising: forming a first substrate having a cavity; positioning one or more resistive heaters in said cavity; coating said cavity and said resistive heaters with one or more materials that are capable of (1) electrically isolating said one or more resistive heaters and (2) conducting heat; and adding a metal hydride material to said cavity.
  • FIG. 1 is a schematic diagram of a metal hydride fuel storage apparatus.
  • metal hydride materials have demonstrated the ability to store hydrogen in percentages by weight ranging from 1-10%, the use of this material as a means to store hydrogen fuel for fuel cells and other power generating techniques has been limited, particularly for portable power applications.
  • the metal hydride is processed as a pressed powder to retain the required porosity, and placed in a vessel made of stainless steel or other high strength material.
  • the vessel has a center flow channel to which the hydrogen outgases and is delivered to the exterior of the container.
  • the limitation to deployment of such storage containers for portable power applications is the power requirements of heating the mass of the containment vessel. The power requirements are not efficient compared to the energy stored as fuel.
  • FIG. 1 shows one embodiment of the invention.
  • a metal hydride fuel storage cartridge 2 comprises: a cavity 4 in a substrate 6 , one or more resistive heaters 8 in said cavity, a cavity coating 10 along said cavity of one or more materials which electrically isolate the resistor and the metal hydride volume (the interior of the cavity), readily conduct heat to uniformly heat the cavity, and provide a diffusion barrier to hydrogen over the temperature range required to outgas the hydrogen from the metal hydride material, a metal hydride material (e.g., Ni, Al, Pd, Ti, or other alloys thereof) 12 , a cap 14 comprising a cap coating 10 of one or more materials which electrically isolate the resistor and the metal hydride volume (the interior of the cavity), readily conduct heat to uniformly heat the cavity, and provide a diffusion barrier to hydrogen over the temperature range required to outgas the hydrogen from the metal hydride material, an outlet 16 and an outlet valve 18
  • a metal hydride fuel storage cartridge 2 comprises: a cavity 4 in a substrate 6 ,
  • the outlet valve is coupled directly to a microfluidic interconnect or other gas distribution system (not shown).
  • An O-ring 24 made of a dense ceramic material can be used to seal the coupling.
  • the substrates can comprise silicon, glass, plastic or ceramic.
  • Coating 10 may comprise silicon dioxide, polymers (e.g., polyimide, poly methylmethacralate (PMMA)) and metals (e.g., copper or cobalt).
  • the hydrogen permaselective membrane material comprises a high strength polymer (e.g., PMMA, Polyimide) and/or metal alloy (e.g., Pd, Ti) which enables selective gas permeation through the membrane as a function of temperature.
  • the thickness and porosity of the thick film porous material that is formed over the membrane can be tailored to provide a pressure gradient such that the hydrogen flow at the exterior of the valve is at ambient pressure, thereby forming the porous membrane pressure relief structure.
  • cavity 10 is formed using micromachining methods, for example, etching, molding or hot embossing.
  • the cavity is coated and the coated cavity is then filled with a metal hydride material (e.g., Ni, Al, Pd, Ti, hydrides or hydrides of similar alloys) using thin/thick film materials synthesis techniques, for example, sol gel spin casting, dip coating, spray deposition or sputter deposition. Shadow masking or other patterning methods are used to selectively deposit the metal hydride in the cavity, completely filling the cavity volume.
  • the cavity is sealed after filling by bonding (shown by arrows 26 ) cap 14 to substrate 6 .
  • the final volume of the sealed cavity is determined by the power requirement to heat the metal hydride with the integrated resistive heaters and outgas the hydrogen through the outlet valve.
  • the cavity has enough strength to withstand 20-50 psi pressure as the hydride is heated.
  • the outlet may be constructed on the cap as a microflow channel which can be formed through the cap using micromachining techniques.
  • the valve is formed by positioning a hydrogen permaselective membrane window structure over the microflow channel outlet.
  • the membrane is formed by bonding the appropriate layer over the window.
  • the porous membrane pressure relief structure is formed over the membrane window by or coating the layers first, then etching the window from the backside selectively.
  • the thickness and porosity of the porous membrane pressure relief structure can be tailored by control of the baking temperature and coating speed for solgel deposited processes, or the temperature and pressure of deposition for vacuum processes.
  • the O-ring can be aligned to a pre-positioned cavity in a gas manifold system, wherein the alignment can be achieved through a package design in order to provide a modular and replaceable cartridge.
  • the hydride storage cavities can be fabricated in arrays to provide more fuel storage capacity while optimizing the power needed to extract the hydrogen fuel from the cartridge.
  • effective heat transfer from the fuel cell heat source can also be used as a means to sustain the heat required to remove the hydrogen fuel from the cartridge.

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Fuel Cell (AREA)
  • Filling Or Discharging Of Gas Storage Vessels (AREA)

Abstract

An apparatus having a first substrate having (1) a cavity, (2) one or more resistive heaters, and (3) one or more coatings forming a diffusion barrier to hydrogen; a second substrate having (1) an outlet valve comprising a pressure relief structure and (2) one or more coatings forming a diffusion barrier to hydrogen, wherein said second substrate is coupled to said first substrate forming a sealed volume in said cavity; a metal hydride material contained within said cavity; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure. Additional apparatuses and methods are also disclosed.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/546,113 filed Oct. 10, 2006 and now issued as U.S. Pat. No. 7,527,659, which is a divisional of U.S. patent application Ser. No. 10/371,876 filed Feb. 21, 2003 now issued as U.S. Pat. No. 7,122,261, which are all incorporated herein by reference.
The United States Government has rights in this invention pursuant to Contract No. DE-AC52-07NA27344 between the United States Department of Energy and the Lawrence Livermore National Security, LLC for the operation of Lawrence Livermore National Laboratory.
BACKGROUND OF THE INVENTION
This invention relates to fuel cells. Work is commonly derived from fuel by a combustion process which uses the pressure of expanding gases to turn a turbine or move a reciprocating piston and, ultimately, to provide torque to a driveshaft. This torque is then usually used for propulsion or to generate electrical power. In the latter case, the electrical power is often reconverted into mechanical work.
SUMMARY OF THE INVENTION
An aspect of the invention includes: an apparatus comprising a first substrate having (1) a cavity, (2) one or more resistive heaters, and (3) one or more electrically isolating, heat conducting coatings; a second substrate having (1) an outlet comprising (a) a hydrogen permaselective membrane and (b) a thick film porous material that forms a pressure relief structure and (2) one or more electrically isolating, heat conducting coatings, wherein the second substrate is bonded to the first substrate forming a sealed volume within the cavity; and a metal hydride material contained within the cavity.
A further aspect of the invention includes a method comprising forming a first substrate having a cavity; positioning one or more resistive heaters in the cavity; coating the cavity and the resistive heaters with one or more materials that are capable of (1) electrically isolating the resistive heaters and (2) conducting heat; filling the cavity with a metal hydride material; forming a second substrate having (1) an outlet comprising (a) a hydrogen permaselective membrane and (b) a thick film porous material that forms a pressure relief structure and (2) one or more electrically isolating, heat conducting coatings; and sealing the cavity by bonding the second substrate to the first substrate.
Another aspect of the invention includes an apparatus comprising a first substrate having an array of cavities containing (1) one or more resistive heaters, and (2) one or more electrically isolating, heat conducting coatings; a second substrate having (1) an array of outlets each comprising (a) a hydrogen permaselective membrane and (b) a thick film porous material that forms a pressure relief structure and (2) one or more electrically isolating, heat conducting coatings, wherein the second substrate is bonded to the first substrate forming a sealed volume within the array of cavities; and a metal hydride material contained within the array of cavities.
Another aspect of the invention includes an apparatus comprising a first substrate having (1) a cavity, (2) one or more resistive heaters, and (3) one or more coatings forming a diffusion barrier to hydrogen; a second substrate having (1) an outlet valve comprising a pressure relief structure and (2) one or more coatings forming a diffusion barrier to hydrogen, wherein said second substrate is coupled to said first substrate forming a sealed volume in said cavity; a metal hydride material contained within said cavity; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.
Another aspect of the invention includes an apparatus comprising: a first substrate having an array of cavities containing (1) one or more resistive heaters, and (2) one or more electrically isolating, heat conducting coatings; a second substrate having (1) an array of outlets each comprising a pressure relief structure and (2) one or more electrically isolating, heat conducting coatings, wherein said second substrate is coupled to said first substrate forming a sealed volume in said array of cavities; and a metal hydride material contained in said array of cavities; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.
Another aspect of the invention includes an apparatus comprising: a first substrate having an array of cavities containing (1) one or more resistive heaters, and (2) one or more coatings forming a diffusion barrier to hydrogen; a second substrate having (1) an array of outlets each comprising a pressure relief structure and (2) one or more coatings forming a diffusion barrier to hydrogen, wherein said second substrate is coupled to said first substrate forming a sealed volume in said array of cavities; and a metal hydride material contained in said array of cavities; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.
Another aspect of the invention includes a method comprising: forming a first substrate having a cavity; positioning one or more resistive heaters in said cavity; coating said cavity and said resistive heaters with one or more materials that are capable of (1) electrically isolating said one or more resistive heaters and (2) conducting heat; and adding a metal hydride material to said cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a metal hydride fuel storage apparatus.
 DETAILED DESCRIPTION
While metal hydride materials have demonstrated the ability to store hydrogen in percentages by weight ranging from 1-10%, the use of this material as a means to store hydrogen fuel for fuel cells and other power generating techniques has been limited, particularly for portable power applications. Typically, the metal hydride is processed as a pressed powder to retain the required porosity, and placed in a vessel made of stainless steel or other high strength material. The vessel has a center flow channel to which the hydrogen outgases and is delivered to the exterior of the container. The limitation to deployment of such storage containers for portable power applications is the power requirements of heating the mass of the containment vessel. The power requirements are not efficient compared to the energy stored as fuel.
Fuel cells disclosed in U.S. patent application Ser. Nos. 09/967,145, 10/261,353, 10/131,846, 10/261,353 assigned to the same assignee can be used in conjunction with the present invention and are all hereby incorporated by reference in their entirety.
Disclosed herein is a metal hydride fuel storage cartridge with integrated heaters. FIG. 1 shows one embodiment of the invention. Referring to FIG. 1, a metal hydride fuel storage cartridge 2 comprises: a cavity 4 in a substrate 6, one or more resistive heaters 8 in said cavity, a cavity coating 10 along said cavity of one or more materials which electrically isolate the resistor and the metal hydride volume (the interior of the cavity), readily conduct heat to uniformly heat the cavity, and provide a diffusion barrier to hydrogen over the temperature range required to outgas the hydrogen from the metal hydride material, a metal hydride material (e.g., Ni, Al, Pd, Ti, or other alloys thereof) 12, a cap 14 comprising a cap coating 10 of one or more materials which electrically isolate the resistor and the metal hydride volume (the interior of the cavity), readily conduct heat to uniformly heat the cavity, and provide a diffusion barrier to hydrogen over the temperature range required to outgas the hydrogen from the metal hydride material, an outlet 16 and an outlet valve 18 comprising a hydrogen permaselective membrane window 20 with a resistive heater (not shown) and a porous membrane pressure relief structure 22. The outlet valve is coupled directly to a microfluidic interconnect or other gas distribution system (not shown). An O-ring 24 made of a dense ceramic material can be used to seal the coupling. The substrates can comprise silicon, glass, plastic or ceramic. Coating 10 may comprise silicon dioxide, polymers (e.g., polyimide, poly methylmethacralate (PMMA)) and metals (e.g., copper or cobalt). The hydrogen permaselective membrane material comprises a high strength polymer (e.g., PMMA, Polyimide) and/or metal alloy (e.g., Pd, Ti) which enables selective gas permeation through the membrane as a function of temperature. The thickness and porosity of the thick film porous material that is formed over the membrane can be tailored to provide a pressure gradient such that the hydrogen flow at the exterior of the valve is at ambient pressure, thereby forming the porous membrane pressure relief structure.
Referring to FIG. 1, cavity 10 is formed using micromachining methods, for example, etching, molding or hot embossing. The cavity is coated and the coated cavity is then filled with a metal hydride material (e.g., Ni, Al, Pd, Ti, hydrides or hydrides of similar alloys) using thin/thick film materials synthesis techniques, for example, sol gel spin casting, dip coating, spray deposition or sputter deposition. Shadow masking or other patterning methods are used to selectively deposit the metal hydride in the cavity, completely filling the cavity volume. The cavity is sealed after filling by bonding (shown by arrows 26) cap 14 to substrate 6. The final volume of the sealed cavity is determined by the power requirement to heat the metal hydride with the integrated resistive heaters and outgas the hydrogen through the outlet valve. The cavity has enough strength to withstand 20-50 psi pressure as the hydride is heated. The outlet may be constructed on the cap as a microflow channel which can be formed through the cap using micromachining techniques. The valve is formed by positioning a hydrogen permaselective membrane window structure over the microflow channel outlet. The membrane is formed by bonding the appropriate layer over the window. Additionally, the porous membrane pressure relief structure is formed over the membrane window by or coating the layers first, then etching the window from the backside selectively. The thickness and porosity of the porous membrane pressure relief structure can be tailored by control of the baking temperature and coating speed for solgel deposited processes, or the temperature and pressure of deposition for vacuum processes. The O-ring can be aligned to a pre-positioned cavity in a gas manifold system, wherein the alignment can be achieved through a package design in order to provide a modular and replaceable cartridge.
Additionally, the hydride storage cavities can be fabricated in arrays to provide more fuel storage capacity while optimizing the power needed to extract the hydrogen fuel from the cartridge. For applications to miniature fuel cells, effective heat transfer from the fuel cell heat source can also be used as a means to sustain the heat required to remove the hydrogen fuel from the cartridge.
All numbers expressing quantities of ingredients, constituents, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the subject matter presented herein are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
While particular operational sequences, materials, temperatures, parameters, and particular embodiments have been described and or illustrated, such are not intended to be limiting. Modifications and changes may become apparent to those skilled in the art, and it is intended that the invention be limited only by the scope of the appended claims.

Claims (24)

1. An apparatus comprising: a first substrate having (1) a cavity, (2) one or more resistive heaters, and (3) one or more coatings forming a diffusion barrier to hydrogen; a second substrate having (1) an outlet valve comprising a pressure relief structure and (2) one or more coatings forming a diffusion barrier to hydrogen, wherein said second substrate is coupled to said first substrate forming a sealed volume in said cavity; a metal hydride material contained within said cavity; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.
2. The apparatus recited in claim 1, wherein said first substrate comprises at least one of silicon, glass, plastic and ceramic.
3. The apparatus recited in claim 1, wherein said second substrate comprises at least one of silicon, glass, plastic and ceramic.
4. The apparatus recited in claim 1, wherein said cavity has enough strength to withstand 20-50 psi pressure as the hydride is heated.
5. The apparatus recited in claim 1, wherein the volume of said cavity is predetermined based on the power requirement to heat the metal hydride with said resistive heaters and outgas the hydrogen through said outlet valve.
6. The apparatus recited in claim 1, wherein said coatings comprises silicon dioxide, polymers, metals, or mixtures thereof.
7. The apparatus recited in claim 1, wherein the pressure relief structure comprises a hydrogen permaselective membrane, wherein said hydrogen permaselective membrane comprises a polymer and/or metal alloy material that enables selective gas permeation through the membrane as a function of temperature.
8. The apparatus recited in claim 1, wherein the pressure relief structure comprises a porous material, wherein said porous material is selected from a group consisting of nickel, silicon, silicon dioxide, silicon nitride, aluminum, alumina, polyimide, palladium, titanium, or alloys thereof.
9. The apparatus recited in claim 1, wherein the pressure relief structure comprises a porous material, wherein a thickness and porosity of said porous material is tailored to provide a pressure gradient such that a hydrogen flow at the outlet valve is at ambient pressure.
10. The apparatus recited in claim 1, wherein the pressure relief structure comprises a porous material, wherein said coupling is accomplished by placing an O-ring around said porous material.
11. The apparatus recited in claim 10, wherein said O-ring is a ceramic material.
12. The apparatus recited in claim 1, wherein said coupling comprises a seal.
13. An apparatus comprising: a first substrate having an array of cavities containing (1) one or more resistive heaters, and (2) one or more electrically isolating, heat conducting coatings; a second substrate having (1) an array of outlets each comprising a pressure relief structure and (2) one or more electrically isolating, heat conducting coatings, wherein said second substrate is coupled to said first substrate forming a sealed volume in said array of cavities; and a metal hydride material contained in said array of cavities; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.
14. The apparatus recited in claim 13, wherein each pressure relief structure comprises a porous material and a hydrogen permaselective membrane.
15. The apparatus recited in claim 13, wherein at least one of the substrates comprises at least one of silicon, glass, plastic and ceramic.
16. The apparatus recited in claim 13, wherein said cavity has enough strength to withstand 20-50 psi pressure as the hydride is heated.
17. The apparatus recited in claim 13, wherein said coatings comprise silicon dioxide, polymers, metals, or mixtures thereof.
18. The apparatus recited in claim 13, wherein the pressure relief structure comprises a hydrogen permaselective membrane, wherein said hydrogen permaselective membrane comprises a polymer and/or metal alloy material that enables selective gas permeation through the membrane as a function of temperature.
19. The apparatus recited in claim 13, wherein the pressure relief structure comprises a porous material, wherein said porous material is selected from a group consisting of nickel, silicon, silicon dioxide, silicon nitride, aluminum, alumina, polyimide, palladium, titanium, or alloys thereof.
20. The apparatus recited in claim 13, wherein the pressure relief structure comprises a porous material, wherein a thickness and porosity of said porous material is tailored to provide a pressure gradient such that a hydrogen flow at the outlet valve is at ambient pressure.
21. The apparatus recited in claim 13, wherein the pressure relief structure comprises a porous material, wherein said coupling is accomplished by placing an O-ring around said porous material.
22. An apparatus comprising: a first substrate having an array of cavities containing (1) one or more resistive heaters, and (2) one or more coatings forming a diffusion barrier to hydrogen; a second substrate having (1) an array of outlets each comprising a pressure relief structure and (2) one or more coatings forming a diffusion barrier to hydrogen, wherein said second substrate is coupled to said first substrate forming a sealed volume in said array of cavities; and a metal hydride material contained in said array of cavities; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.
23. A method comprising:
forming a first substrate having a cavity;
positioning one or more resistive heaters in said cavity;
coating said cavity and said resistive heaters with one or more materials that are capable of (1) electrically isolating said one or more resistive heaters and (2) conducting heat; and
adding a metal hydride material to said cavity.
24. The method recited in claim 23, further comprising bonding a cap to the first substrate for sealing said cavity.
US12/409,392 2003-02-21 2009-03-23 Metal hydride fuel storage and method thereof Expired - Lifetime US7771887B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US12/409,392 US7771887B2 (en) 2003-02-21 2009-03-23 Metal hydride fuel storage and method thereof

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/371,876 US7122261B2 (en) 2003-02-21 2003-02-21 Metal hydride fuel storage and method thereof
US11/546,113 US7527659B2 (en) 2003-02-21 2006-10-10 Metal hydride fuel storage and method thereof
US12/409,392 US7771887B2 (en) 2003-02-21 2009-03-23 Metal hydride fuel storage and method thereof

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US11/546,113 Continuation US7527659B2 (en) 2003-02-21 2006-10-10 Metal hydride fuel storage and method thereof

Publications (2)

Publication Number Publication Date
US20090184008A1 US20090184008A1 (en) 2009-07-23
US7771887B2 true US7771887B2 (en) 2010-08-10

Family

ID=32868431

Family Applications (3)

Application Number Title Priority Date Filing Date
US10/371,876 Expired - Fee Related US7122261B2 (en) 2003-02-21 2003-02-21 Metal hydride fuel storage and method thereof
US11/546,113 Expired - Fee Related US7527659B2 (en) 2003-02-21 2006-10-10 Metal hydride fuel storage and method thereof
US12/409,392 Expired - Lifetime US7771887B2 (en) 2003-02-21 2009-03-23 Metal hydride fuel storage and method thereof

Family Applications Before (2)

Application Number Title Priority Date Filing Date
US10/371,876 Expired - Fee Related US7122261B2 (en) 2003-02-21 2003-02-21 Metal hydride fuel storage and method thereof
US11/546,113 Expired - Fee Related US7527659B2 (en) 2003-02-21 2006-10-10 Metal hydride fuel storage and method thereof

Country Status (1)

Country Link
US (3) US7122261B2 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9512002B2 (en) 2012-12-21 2016-12-06 Cella Acquisition Limited Hydrogen storage pellet

Families Citing this family (31)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7122261B2 (en) * 2003-02-21 2006-10-17 The Regents Of The University Of California Metal hydride fuel storage and method thereof
US7666539B2 (en) * 2003-06-27 2010-02-23 Ultracell Corporation Heat efficient portable fuel cell systems
US7276096B2 (en) * 2003-06-27 2007-10-02 Ultracell Corporation Fuel processor dewar and methods
US8318368B2 (en) * 2003-06-27 2012-11-27 UltraCell, L.L.C. Portable systems for engine block
US7655337B2 (en) 2003-06-27 2010-02-02 Ultracell Corporation Micro fuel cell thermal management
WO2005004257A2 (en) * 2003-06-27 2005-01-13 Ultracell Corporation Efficient micro fuel cell systems and methods
US8821832B2 (en) 2003-06-27 2014-09-02 UltraCell, L.L.C. Fuel processor for use with portable fuel cells
EP1641671B1 (en) 2003-06-27 2015-06-24 Portaclave LLP Portable fuel cartridge for fuel cells
US20060156627A1 (en) * 2003-06-27 2006-07-20 Ultracell Corporation Fuel processor for use with portable fuel cells
GB0315280D0 (en) * 2003-06-30 2003-08-06 Voller Energy Ltd Improvements relating to fuel cell systems
US8114554B2 (en) * 2003-09-16 2012-02-14 The Gillette Company—South Boston Enhanced fuel delivery for direct methanol fuel cells
WO2005037421A2 (en) * 2003-10-14 2005-04-28 Advanced Technology Materials, Inc. Hydrogen generation
US20050255368A1 (en) * 2004-05-12 2005-11-17 Ultracell Corporation, A California Corporation High surface area micro fuel cell architecture
US7968250B2 (en) 2004-06-25 2011-06-28 Ultracell Corporation Fuel cartridge connectivity
US7648792B2 (en) 2004-06-25 2010-01-19 Ultracell Corporation Disposable component on a fuel cartridge and for use with a portable fuel cell system
KR20070064584A (en) * 2004-07-08 2007-06-21 다이렉트 메탄올 퓨얼 셀 코포레이션 Fuel Cell Cartridges and Fuel Transport Systems
US7205060B2 (en) 2004-08-06 2007-04-17 Ultracell Corporation Method and system for controlling fluid delivery in a fuel cell
US7807313B2 (en) * 2004-12-21 2010-10-05 Ultracell Corporation Compact fuel cell package
US20080029156A1 (en) * 2006-01-19 2008-02-07 Rosal Manuel A D Fuel cartridge
WO2008020876A2 (en) * 2006-01-19 2008-02-21 Direct Methanol Fuel Cell Corporation Fuel cartridge
KR100790688B1 (en) * 2006-12-26 2008-01-02 삼성전기주식회사 Fuel Cell with Hydrogen Storage Tank
WO2010081942A1 (en) * 2008-12-05 2010-07-22 Alex Hr Roustaei Hydrogen cells or microcells with a hydrogen generator
PL2681792T3 (en) * 2011-02-28 2021-05-31 Nicolas Kernene Energy unit with safe and stable hydrogen storage
US9718679B2 (en) * 2011-06-27 2017-08-01 Invensense, Inc. Integrated heater for gettering or outgassing activation
US9540230B2 (en) 2011-06-27 2017-01-10 Invensense, Inc. Methods for CMOS-MEMS integrated devices with multiple sealed cavities maintained at various pressures
US9738512B2 (en) 2012-06-27 2017-08-22 Invensense, Inc. CMOS-MEMS integrated device including multiple cavities at different controlled pressures and methods of manufacture
JP6671590B2 (en) * 2015-07-28 2020-03-25 国立大学法人 鹿児島大学 Hydrogen gas production apparatus and hydrogen gas production method
TWI591890B (en) * 2015-08-21 2017-07-11 亞太燃料電池科技股份有限公司 A heating and safety device for canister, gas storage canister and hydrogen storage canister
CN106469817B (en) * 2015-08-21 2019-03-12 亚太燃料电池科技股份有限公司 Heating and safety device for container, gas storage tank and hydrogen storage tank
US11078075B2 (en) * 2015-12-31 2021-08-03 Taiwan Semiconductor Manufacturing Company Ltd. Packaging method and associated packaging structure
US10714795B2 (en) * 2017-05-01 2020-07-14 Infineon Technologies Ag Monitoring battery cell internal pressure

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6544400B2 (en) * 2000-03-30 2003-04-08 Manhattan Scientifics, Inc. Portable chemical hydrogen hydride system
US6686076B2 (en) * 2000-04-10 2004-02-03 Excellatron Solid State, Llc Electrochemical conversion system
US7527659B2 (en) * 2003-02-21 2009-05-05 Lawrence Livermore National Security, Llc Metal hydride fuel storage and method thereof

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002531246A (en) 1998-12-02 2002-09-24 マサチューセッツ・インスティチュート・オブ・テクノロジー Integrated palladium-based micromembrane for hydrogen separation and hydrogenation / dehydrogenation reactions
US6638654B2 (en) * 1999-02-01 2003-10-28 The Regents Of The University Of California MEMS-based thin-film fuel cells
US6569553B1 (en) 2000-08-28 2003-05-27 Motorola, Inc. Fuel processor with integrated fuel cell utilizing ceramic technology
US6916565B2 (en) 2000-12-21 2005-07-12 Casio Computer Co., Ltd. Power supply system, fuel pack constituting the system, and device driven by power generator and power supply system
US6824905B2 (en) 2001-01-15 2004-11-30 Casio Computer Co., Ltd. Power supply system and device driven by power supply system
WO2002059993A2 (en) 2001-01-24 2002-08-01 Casio Computer Co., Ltd. Integrated fuel pack, reformer and gas purification device for fuel cell power generation system____________
US7169367B2 (en) 2002-04-05 2007-01-30 Casio Computer Co., Ltd. Chemical reaction apparatus and power supply system

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6544400B2 (en) * 2000-03-30 2003-04-08 Manhattan Scientifics, Inc. Portable chemical hydrogen hydride system
US6686076B2 (en) * 2000-04-10 2004-02-03 Excellatron Solid State, Llc Electrochemical conversion system
US7527659B2 (en) * 2003-02-21 2009-05-05 Lawrence Livermore National Security, Llc Metal hydride fuel storage and method thereof

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9512002B2 (en) 2012-12-21 2016-12-06 Cella Acquisition Limited Hydrogen storage pellet

Also Published As

Publication number Publication date
US20090184008A1 (en) 2009-07-23
US7122261B2 (en) 2006-10-17
US7527659B2 (en) 2009-05-05
US20040166385A1 (en) 2004-08-26
US20070031586A1 (en) 2007-02-08

Similar Documents

Publication Publication Date Title
US7771887B2 (en) Metal hydride fuel storage and method thereof
JP5564436B2 (en) Transmission barrier layer
US6815052B2 (en) Filled diamond foam material and method for forming same
US6929866B1 (en) Composite foam structures
JP5554747B2 (en) Gas seal composite and apparatus comprising the gas seal composite
CN104904052A (en) Heater assembly, hydrogen generator, and method of providing hydrogen
WO2008005185B1 (en) Novel fuel cells and methods of manufacturing the same
GB2042393A (en) Method of diffusion bonding duplex sheet cladding to substrates
US11171345B2 (en) Gas storage system
Morse et al. Metal hydride fuel storage and method thereof
US7560170B2 (en) Surface modification of porous metal substrates using cold spray
US20060172141A1 (en) Joints and methods of making and using
JP2023513009A (en) Rapid Induction Sinter Forging for Roll-to-Roll Continuous Manufacturing of Thin Films
US20230384041A1 (en) Latent heat storage
WO2017184580A1 (en) Methods for manufacturing ceramic and ceramic composite components and components made thereby
Stöver et al. MEA/cell preparation methods: E urope/USA
Solov’ev et al. Synthesis and investigation of porous Ni-Al substrates for solid-oxide fuel cells
Windes et al. Fabrication methods of a leaky SOFC design
Soloviev et al. Solid oxide fuel cell on porous Ni-Al support
Chaparala et al. MIT-OSU-HP Focus center on non-lithographic Technologies for MEMS and nEMS
Yu et al. Fabrication of Microchanneled Reformer for Portable Fuel Cell
JPH04272185A (en) Manufacture of metallic tube equiped with metal-base composite material film
EP1613465A2 (en) Surface modification of porous metals

Legal Events

Date Code Title Description
STCF Information on status: patent grant

Free format text: PATENTED CASE

FEPP Fee payment procedure

Free format text: PAYOR NUMBER ASSIGNED (ORIGINAL EVENT CODE: ASPN); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

Free format text: PAYER NUMBER DE-ASSIGNED (ORIGINAL EVENT CODE: RMPN); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

FPAY Fee payment

Year of fee payment: 4

AS Assignment

Owner name: U.S. DEPARTMENT OF ENERGY, DISTRICT OF COLUMBIA

Free format text: CONFIRMATORY LICENSE;ASSIGNOR:LAWRENCE LIVERMORE NATIONAL SECURITY, LLC;REEL/FRAME:033920/0583

Effective date: 20140828

AS Assignment

Owner name: LAWRENCE LIVERMORE NATIONAL SECURITY, LLC, CALIFOR

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:THE REGENTS OF THE UNIVERSITY OF CALIFORNIA;REEL/FRAME:038484/0655

Effective date: 20160414

MAFP Maintenance fee payment

Free format text: PAYMENT OF MAINTENANCE FEE, 8TH YEAR, LARGE ENTITY (ORIGINAL EVENT CODE: M1552)

Year of fee payment: 8

MAFP Maintenance fee payment

Free format text: PAYMENT OF MAINTENANCE FEE, 12TH YEAR, LARGE ENTITY (ORIGINAL EVENT CODE: M1553); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

Year of fee payment: 12